TeroMatec-welding-cored-wire

TeroMatec

®

Self shielding, welding cored wire technology for wear protection, rebuilding & repair

Enduring Performance…

Stronger, with

Castolin Eutectic

Self shielding peripheric arc system ensures : Fastest weld deposition rates Higher welding duty cycles On site capability without shielding gas supplies Optimised alloy weld properties for longer service life Maximum cost savings & productivity

TeroMatec® TeroMatec® CORED WELDING WIRES TeroMatec® is a self shielded arc welding process (Open Arc/FCAW) using specially formulated flux cored wire electrodes. The self shielded peripheric arc conception includes a wide range of custom made alloys optimised for industrial wearfacing, rebuilding and repair solutions with many advantages : No shielding gas requirements Solidified slag Wire guide / contact tube Molten slag Fastest weld deposition rates Cored wire Higher welding duty cycles Particles-elements/compounds Efficient weld metal recovery Gas shield created by compounds Stock reduction opportunities Arc and Metal transfer Ease of use by semi skilled operators Maximum savings & productivity

NO SHIELDING GAS REQUIREMENTS

Weld pool Solidified weld metal

Self shielding peripheric arc

The TeroMatec® process requires no costly investments or complicated manipulation of heavy gas cylinders, regulators, flowmeters, mixers, hoses etc. TeroMatec®’s autonomous self shielding peripheric arc is designed for outdoor use where on-site wind or draught conditions would simply blow away any external protective gas (GMAW) causing porous, defective welds.

FASTEST WELD DEPOSITION RATES

HIGHER WELDING DUTY CYCLES

The deposition rate of TeroMatec® flux cored electrodes is remarkable reaching 4 kg/h with the Ø1.6 mm and almost 10 kg/h with the Ø2.8 mm due to peripheric arc current density effects. Furthermore, by increasing the electrode “stick out” (distance between the contact tube tip and the workpiece) from 50mm to 75mm, the deposition rate can be boosted over 12 kg/h due to electrical resistance heating effects whilst reducing heat input and dilution with the base metal.

The welding duty cycle (X) is simply the % relationship between the effective arc welding time (t1) and the total time involved (t1 + t2) where t2 is the non productive time between the arc welding cycles. Thus TeroMatec® duty cycles easily reach over 90% in automatic mode compared with MMA stick electrodes which peak around 40%. The higher duty cycle for TeroMatec® is due to : no need to keep stopping & changing electrodes repetitive striking & restriking eliminated less post weld slag cleaning required fewer stop-start weld crater defects to grind

Deposition rate (kg/h) 400% extra

300%

Arc On

X=

extra

t1 x 100 % t1 + t2

Arc Off

Time High efficiency manual electrode

Current (A)

2

TeroMatec®

X≈ 80-90%

Manual electrode

X≈ 40%

Stronger with Castolin Eutectic www.castolin.com

EFFICIENT WELD METAL RECOVERY (

%)

The weld metal recovery (sometimes called yield or efficiency) is simply the ratio of the mass of weld deposited to the total mass of the original welding electrode. Thus TeroMatec® cored wires have an excellent weld metal recovery ratio reaching 90% to 95% whilst MMA stick electrodes only reach around 65% due to higher slag volumes and repetitive stub end losses.

In other words, TeroMatec® ensures that virtually all the weight of purchased cored wire ends up as a useful weld deposit thus reducing consumable costs.

= 1000g

= 1000g

950 g

650 g

MMA

- 65%

TeroMatec

- 95%

STOCK REDUCTION OPPORTUNITIES As a 15kg TeroMatec® spool represents around 22kg of MMA stick electrodes for the same quantity of required weld deposit, this represents a potential to cut welding consumable stocks by over 30% !

Additionally, when a single spool Ø 1.2 or 1.6 mm TeroMatec® is considered, its all round application welding capabilities can eliminate the need to stock separate packs of stick electrodes in 2.4mm, 3.2mm, 4.0mm & 5.0mm sizes thus further reducing inventory costs.

EASE OF USE BY SEMI SKILLED OPERATORS Relatively little training is required for the TeroMatec® process (compared with MMA) which makes it easy to learn by semi-skilled operators due to the self regulating nature of the arc, variable stick out capability, better visibility and absence of external shielding gases. Furthermore, powerful flux deoxidisers in the TeroMatec® cored wire enable direct welding on rusty or oxidised steel surfaces without the meticulous precleaning needed for the GMAW process, especially when access is limited.

MAXIMUM SAVINGS & PRODUCTIVITY Numerous studies by industry show that labour costs are the biggest single expense in welding. As skilled labour rates continue to rise inexorably, cut and control your welding costs with TeroMatec®.

TeroMatec® systems significantly increase cost savings and productivity over both Mig / Mag & MMA processes due to the ease of use by semi skilled operators, the incomparable weld deposition rates giving superior performance and service life.

Stronger with Castolin Eutectic www.castolin.com

3

TeroMatec® TeroMatec® MANUFACTURING FACILITIES The TeroMatec® range of high performance cored electrodes are formulated, developed and manufactured in Castolin Eutectic’s own modern plants using specially designed production equipment and procedures in accordance with ISO 9001 and EN 29001 quality assurance standards.

Each TeroMatec® batch after wire drawing and baking, is weld tested for consistent chemistry, properties & operability before precision spiral spooling and protective packaging for stock.

metal strip pre-forming roll flux finishing rolls

ø 1,2 mm ø 1,6 mm ø 2,4 mm ø 2,8 mm

Self shielding flux ingredients, arc ionising stabilisers, fine grain inoculants, powerful deoxidisers, metallurgical refining agents, selected alloying elements, carbide compounds, etc.

Steel strip

core wire

SELF SHIELDED PERIPHERIC ARC Thanks to TeroMatec®’s self shielding and high current density characteristics, it can be welded at lower welding currents than a solid wire whilst keeping a stable metal transfer across the arc due to ionising elements in the core. Additionally, the lower heat input and presence of powerful deoxidising fluxes means that TeroMatec® weld deposits have better bonding, lower dilution, superior microstructure properties and minimal heat affected zones for maximum service performance.

UNIQUE ANTI-WEAR ALLOYS Solid Mag wires can only be manufactured in metallurgical alloys which can be cast and easily drawn down to final diameters. The TeroMatec® cored electrode concept completely overcomes such limitations and unique metallurgical alloys have been formulated with high density, ultra-hard micro constituants in Fe matrices. Thus the wide TeroMatec® alloy range provides cost effective solutions for most wear problems found in industry.

4

Stronger with Castolin Eutectic www.castolin.com

Abr as Ero ion sio Imp n a Fric ct ti He on at Cor ro Cav sion it Reb ation ui ld ing B as eM eta l

TeroMatec® flux cored wires Technical Data For Joining, Buttering and Rebuilding

690

Fe

2010

Fe

4226

EO 8340

Bucket blades, grabs, leveller blades, tooth-holders on Tensile strength : 600-670 N/mm² mechanical shovels Elongation (l=d) : 45-55 % Hardness : 170-210 HV Foundry defects in cast steel, shrinkage cavities or blowholes in semihard or cast steel.

Tensile strength : 560-640 N/mm² Hardness : 260-310 HV

Fe

Repair of foundry defects in nodular or spheroidal graphite grades of cast iron - porosity, blow holes or shrinkage cavities.

Tensile strength ~475 N/mm2 Hardness ~50 HRC Annealed ~24 HRC

Fe

For joining, fabrication & repair of mild and low alloy steels, galvanised steels, used for containers, vessels, hoppers, truck bodies, piping systems, machinery cast steel parts.

Tensile strength : 480 N/mm² Elongation (l=d) : 20% Yield stress= 400 N/mm2

For anti-wear Coatings high resistant to Impact, metal/metal Friction, and slight Abrasion Rolling mill slide rods, shovel buckets, mobile crane wheels, rails.

Tensile strength : 710-790 N/mm² Elongation (l=d) : 20-30 % Hardness : 220-270 HV Hardness after workhardening : 400HV

3205

Fe

3206

Fe

Crusher hammers, rolls, cranes, jaws, power shovel or dredge buckets, pump parts.

Hardness ~300 HV Work hardened ~45 HRC

3220

Fe

Mechanical shovel teeth, crusher hammers and rolls, grab edges.

Hardness : 230-280 HV

3302

Fe

For intermediate layers and multi-pass anti-wear coatings, joining of large parts of dissimilar composition, rail points, crusher bars and jaws, drive sprockets.

Tensile strength : 580-660 N/mm² Elongation (l=d) : 35-45 % Hardness : 180-220 HV

ES 4530

Fe

Railway retarder beams and wagon brakes, outside parts in hydroelectric power stations, defects in chromium cast steel. For submerged arc welding.

Tensile strength : 800-1000 N/mm² Hardness : 290-340 HV Hardness after welding : 340-420 HV

For anti-wear Coatings resistant to moderate Abrasion combined with Impact and Pressure Fe

Crusher hammers, bars, anvils, casings, mechanical shovel bucket teeth & lips, dragline grab teeth, scraper blades.

Hardness ~59 HRC

4327 4415

Fe

Ground augers, percussion grabs, dragline teeth and leading edges, gravel pumps, conveyor screws.

Hardness : 52-57 HV

Fe

Crusher bars and cylinders, feed screws, clay crushers, conveyor belts, waste disposal crusher hammers.

Hardness : 49-54 HV

4625

4923

Fe

Crusher hammers and bars, impact and casing screens, bucket teeth and lips, scraper blades.

Hardness : 54-59 HV

For anti-wear Coatings resistant to high Abrasion and Erosion Sinter crushers and fans, hot sieves, screens and bells.

Hardness : 61-66 HV

Unique NanoAlloy for transport screws, furnace chutes, exhaust fans, cyclones, conveyor, mixers, scrapers, screws, screens.

Hardness ~70 HRC

Fe

4601

Fe

Conveyor screws, rolls, crusher pinions and grinders, dragline and pump parts.

Hardness : 52-57 HV

Fe

Press spindle segment heads, mixer segments, blades and scraper, wear plates, induction fans, drag chains.

Hardness : 65-70 HV

4630

4660

Fe

Jaw crushers, mixer paddles, pump wheels, mould screws.

Hardness : 59-64 HV

3952 w Ne duct o 4395N Pr

Main application

Fe

Secondary application

Stronger with Castolin Eutectic www.castolin.com

5

TeroMatec® THE COMPLETELY MOBILE TeroMatec® SYSTEM Wire Feeder developed specially for heavy duty wear protection applications.

Unit powered by the open arc voltage.

Fitted contactor (up to 400A) for safe operation, live torch>400A Fitted solenoid for gas shielding.

Designed for wires from 1.2mm to 2.8mm with a simple combination of rollers.

High feeding force: 4 wheel drive knurled rollers.

Fully protected feeding system.

Self regulating wire speed. Accepts 15kg and 25kg spool types.

Easy to maintain.

Euro connection to accept any torch( water cooling option).

Front panel of the TeroMatec® Wire feeder 600

TeroMatec® Wire Feeder 600 is designed for coating and joining with open-arc wires in the field. Connected directly to the arc voltage. No mains connection is needed. It operates with any welding power source (with any DC power source)*. TeroMatec® Wire Feeder 600 is easier to use than a manual electrode as a constant arc length is assured by self regulation of the variable wire speed. Any arc length changes are automatically compensated via the arc voltage driving the wire speed. This feature is unique to TeroMatec®. * Suitable are CE marked welding power sources or those with OCV<75V.

Exclusive wire feeding system, ensures smooth push feeding speeds for TeroMatec® flux cored electrodes.

Technical Specifications Input voltage range Input current for control circuits and motor Welding current range Welding wire diameters Duty cycle . 60% . 60%

TeroMatec® Wire Feeder 600 21-110 V DC 10A max ( input fused at 10A ) 50-600A (depending upon power source) 1.2mm to 2.8mm 400A contactor - non live torch 600A live torch

Consult your Castolin Eutectic Application Specialist about the range of CastoMatec welding power sources.

6

Stronger with Castolin Eutectic www.castolin.com

TeroMatec速 applications For your critical applications Wear phenomena

Industry

Parts

Abrasion + Pressure + Impact

Cement

Rollers of vertical roller mill

Abrasion + erosion

Sugar cane

Teeth of a sugar cane crusher

Abrasion

Open cast mining

Bucket teeth

Impact + abrasion

Glass works

Hammer

Impact + hot abrasion

Iron and steel works

Sinter Crush tooth

Friction + abrasion

Pulp and paper

Counter-knife

Stronger with Castolin Eutectic www.castolin.com

7

TeroMatec速 applications For your critical applications

8

Wear phenomena

Industry

Parts

Friction + abrasion + impact + erosion

Civil engineering

Drill sleeve cutter

Abrasion

Thermal power plants

Coal screw vanes

Impact + abrasion

Quarry

Limestone hammer

Impact + abrasion

Refuse recycling

Crushing claws

Friction

Forging

Hydraulic casing

Friction + abrasion + corrosion

Pulp and paper

Screw conveyor

Stronger with Castolin Eutectic www.castolin.com

TeroMatec® applications Application Cement Industry A cement plant installed two new waste feeding lines into the kiln burner. Waste is pumped at 32 m/s speed through 60m and 90m long feeding lines. Previous OEM solutions consisted of standard mild steel straight tubes with internally basalt protected elbows which lasted only 3 weeks. When the installation was operating, the noise of multiple impacts could be heard due to scrap metal or stone particles in the waste feedstock. This caused high wear rate failures of the basalt lining.

Wear is usually localized at the elbow entry

First line installation (passing through platform floor).

Second line awaiting installation.

Solution After a successful month’s testing on one CastoTube® elbow coated on the inlet side with NanoAlloy® TM 4395N and on the remaining section with a TM 4666 coating, the customer decided to build the whole line with CastoTube®. Critical parts of the line such as the elbow inlets had NanoAlloy® protection, while the rest of the installation including the straight tubes, had the TM 4666 internal coating.

Sample of a NanoTube, yellow section wearfaced with NanoAlloy® TM 4395N and red one coated with standard CastoTube® alloy TM 4666

Elbows above the platform constructed from CastoTubes with NanoAlloy TM4395N coating have yellow inscriptions. Standard TM 4666 CastoTubes have red inscriptions.

Cost saving Before Downtime cost per day Previous service life

With Castolin Eutectic procedure 99 600 € 21 days

Cost of Castolin Eutectic procedure Actual service life

62 300 € 300 days

Stronger with Castolin Eutectic www.castolin.com

LPF *

* Life Prolonging Factor

9%

+132

Application part of the Polish TeroLink® databse

9

TeroMatec® Castolin Eutectic

Training

Castolin Eutectic Locations

The unique Terolink database of Castolin Eutectic contains more than 8,000 fully documented approved applications from around the globe.

The case studies include photographs, technical data, detailed descriptions and cost-saving analyses.

Manufacturing

Product Portfolio - Widest in the Industry

R&D-Wear Test Laboratory

Together with our sister company, the Messer Group, we can offer our customers a very powerful range of products and services. Being «Part of the Messer World» means:

Metallurgical Laboratory

10

To increase customer knowhow in wear technology and repair techniques, we have developed a full line of seminars and training programs, teaching all relevant personnel from welders and engineers to sales teams and managing directors.

Investment of over €420 million More than 6,000 motivated employees Over 100 factories to meet customer needs Technical sales support in over 120 countries 2,000 technical sales people in the field with our customers every day

Micrograph of Wear Phenomena

Stronger with Castolin Eutectic www.castolin.com

History of Castolin Eutectic 1906: Foundation of Castolin in Lausanne, Switzerland by Jean-Pierre Wasserman. His stroke of genius: to discover a way of welding cast iron at low temperature; in the following years, this innovation was further developed for all industrial metals including aluminium alloys.

1940: Foundation of Eutectic Welding Alloys Corporation in New York 1952: Foundation of Castolin France 1959: Foundation of Eutectic Japan Ltd 1962: Foundation of Eutectic India Ltd. 1960’s: International consolidation under Castolin Eutectic 1970’s: Creation of training centers for Maintenance & Repair technologies 1978: Establishment of World Head Quarters in St-Sulpice, Switzerland 2000: Merger with Messer Cutting & Welding and creation of the MEC Group - Messer Eutectic Castolin 2005: Part of the Messer World 2006: 100 years of innovation, service and quality.

Addresses of Castolin Eutectic Companies in Europe Austria, Hungary, South East Europe Castolin GmbH Brunner Strasse 69 1235 Wien +43 (0)1 869 45 41 0

Netherlands SA Messer Eutectic Castolin Benelux NV Rotterdamseweg 406 2629 HH Delft +31 (0)15 256 92 03

Sweden, Denmark, Finland Castolin Scandinavia AB Transportgatan 37 42204 Hisings-Backa, Sweden +46 (0)31 570 470

Belgium MEC Benelux nv / sa – Castolin Eutectic Rue des Ateliers, 11 7850 Enghien (Edingen) +32 (0)2 888 24 51

Norway Castolin Scandinavia NUF Hammaren 13 4056 Tananger +47 (0)516 925 10

Czech Republic Messer Eutectic Castolin spol.s.r.o.

Trojska 80/122 18200 Praha 8 +420 2-830 900 77

Poland Messer Eutectic Castolin Sp.z.o.o.

P.O. Box 502, ul. Robotnicza 2 44-100 Gliwice +48 (0)32 230 67 36

Switzerland Messer Eutectic Castolin Switzerland SA Swiss Market Center Industriestrasse 34 8108 Dällikon +41(0)44 847 17 17

France Messer Eutectic Castolin SARL 22, Av. du Québec BP 325 Z.A. Courtaboeuf 1- Villebon 91958 Courtaboeuf Cedex +33 (0)1 69 82 69 82

Russia Messer Eutektik Castolin Ltd. Ul. Bolschaja Tulskajya 10/9, Office 9506 115191 Moscow +7 (0)495 771 74 12

Germany Castolin GmbH Gutenbergstrasse 10 65830 Kriftel +49 (0)6192 403 0

Spain Castolin Iberica S.A. P. I. de Alcobendas c/ San Rafael, 6 28108 Alcobendas (Madrid) +34-(0)91 490 03 00

Turkey Castolin Kaynak San. Ve Tic. Ltd. Sti. Yukari Dudullu Mahallesi Bostanci Yolu Sehit Sokak 53 34775 Ümraniye / Istanbul +90 (0)216 313 28 00 United Kingdom & Ireland Castolin Eutectic Ltd. Unit 10, Merse Road North Moons Moat Redditch B98 9NZ +44 (0)1527 582 200

Statement of Liability: Due to variations inherent in specific applications, the technical information contained herein, including any information as to suggest product applications or results, is presented without representation or warranty, expressed or implied. Without limitation, there are no warranties of merchantability or of fitness for a particular purpose. Each process and application must be fully evaluated by the user in all respects, including suitability, compliance with applicable law and non-infringement of the rights of others, and Castolin Eutectic and its affiliates shall have no liability in respect there of.

Your resource for protection, repair and joining solutions www.castolin.com

www.eutectic.com

Stronger with Castolin Eutectic www.castolin.com

11

Stronger with...

Castolin Eutectic WEAR & FUSION TECHNOLOGY

Ask for a demonstration from our Application Specialists.

-> www.castolin.com <<<

-> www.eutectic.com <<<